US20040180241A1 - Coated cemented carbide insert - Google Patents
Coated cemented carbide insert Download PDFInfo
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- US20040180241A1 US20040180241A1 US10/760,387 US76038704A US2004180241A1 US 20040180241 A1 US20040180241 A1 US 20040180241A1 US 76038704 A US76038704 A US 76038704A US 2004180241 A1 US2004180241 A1 US 2004180241A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
- B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
- C23C28/044—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material coatings specially adapted for cutting tools or wear applications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
- B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
- B23B27/141—Specially shaped plate-like cutting inserts, i.e. length greater or equal to width, width greater than or equal to thickness
- B23B27/145—Specially shaped plate-like cutting inserts, i.e. length greater or equal to width, width greater than or equal to thickness characterised by having a special shape
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C27/00—Alloys based on rhenium or a refractory metal not mentioned in groups C22C14/00 or C22C16/00
- C22C27/04—Alloys based on tungsten or molybdenum
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
- C23C16/36—Carbonitrides
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
- C23C16/40—Oxides
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
- C23C28/048—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material with layers graded in composition or physical properties
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/40—Coatings including alternating layers following a pattern, a periodic or defined repetition
- C23C28/42—Coatings including alternating layers following a pattern, a periodic or defined repetition characterized by the composition of the alternating layers
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
- C23C30/005—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process on hard metal substrates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2200/00—Details of cutting inserts
- B23B2200/24—Cross section of the cutting edge
- B23B2200/245—Cross section of the cutting edge rounded
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2224/00—Materials of tools or workpieces composed of a compound including a metal
- B23B2224/04—Aluminium oxide
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2224/00—Materials of tools or workpieces composed of a compound including a metal
- B23B2224/32—Titanium carbide nitride (TiCN)
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2228/00—Properties of materials of tools or workpieces, materials of tools or workpieces applied in a specific manner
- B23B2228/10—Coatings
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12583—Component contains compound of adjacent metal
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/2495—Thickness [relative or absolute]
- Y10T428/24967—Absolute thicknesses specified
- Y10T428/24975—No layer or component greater than 5 mils thick
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
- Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
- Y10T428/264—Up to 3 mils
- Y10T428/265—1 mil or less
Definitions
- the present invention relates to a coated cemented carbide cutting tool insert for the machining in general of steel in applications having high requirements on wear resistance and toughness behaviour of the cutting edge.
- the tool is particularly suitable for the turning of stainless steels.
- Multilayer coatings comprising first and second coating layers of different materials which are alternately laminated on the substrate, each of the first coating layers having a first thickness and each of the second coating layers having a second thickness are known.
- the two layers should preferably have a different crystal structure and/or at least different lattice spacings.
- One example of such a structure is when the Al 2 O 3 growth periodically is interrupted by a short TiN deposition process resulting in a (Al 2 O 3 +TiN) x multilayer structure see e.g. Proceedings of the 12th European CVD Conference page pr.8-349.
- GB 2048960A discloses a multilayer coating with a multiplicity of alternating layers of 0.02 to 0.1 ⁇ m consisting of hard material of different compositions.
- U.S. Pat. No. 4,599,281 discloses a multilayer coating with alternating layers of an aluminium-boron mixed oxide and another oxide layer of e g Ti(C,N,O). Dreyer and Kolaska, Metals Society (Book 278), London, England (1982) 112-117 report an A—O—N multilayer.
- U.S. Pat. No. 4,984,940 Bryant et al. disclose a cutting insert composed of a cemented carbide substrate with 6.1-6.5 wt % cobalt, a coating including a base layer of titaniumcarbonitride followed by a multilayered coating consisting of a plurality of alumina layers.
- a cemented carbide substrate with a coating comprising 6-8 alumina layers is also claimed in U.S. Pat. No. 5,700,569.
- WO 99/58738 describes a tool consisting of a hard wear resistant substrate and a CVD multilayer of about 50 layers.
- EP-A-1103635 claims a cutting tool consisting of a cemented carbide substrate with 9.0-10.9 wt % cobalt and a coating comprising a medium temperature CVD (MTCVD) deposited TiCN-layer and a multilayer composed of totally 7-41 layers of ⁇ -alumina and TiN or Ti(C,N).
- MTCVD medium temperature CVD
- EP-A-1245698, EP-A-1245700, and EP-1209255 also relate to multilayer coatings.
- a coated cemented carbide cutting tool insert comprising a first, innermost layer system of at least two layers of TiC x N y O z with x+y+z ⁇ 1; and a second multilayer system comprising from about 5 to about 31 alternating layers of Al 2 O 3 and TiC x N y O z (x+y+z ⁇ 1), the Al 2 O 3 -layers having an individual layer thickness of ⁇ 0.5 ⁇ m and the TiC x N y O z -layers from about 0.01 to about 0.2 ⁇ m with a total thickness of the multilayer from about 1.0 to about 4.0 ⁇ m, and wherein the multilayer is exposed along the edge line and into the rake and flank face, such that the exposure on the rake face (a) is greater than about 0.03 and less than about 0.9 mm, the exposure on the flank face (b) is greater than about 0.02 and less than about 0.2 mm and a>b.
- FIG. 1. is a scanning electron micrograph (SEM) of a cross-section of the coating according to the present invention in which:
- D. multilayer (Al 2 O 3 +TiN) 6 Al 2 O 3 and
- E. TiN+TiC+TiN.
- FIG. 2. 1 is a schematic of the cross-section of the edge without a post-treatment.
- FIG. 2. 2 is a schematic of the cross-section of the edge with a post-treatment according to the invention where the outermost coating E is removed.
- FIG. 2. 3 is a schematic of the cross-section of the edge with a post-treatment according to the invention where the outermost coating E and the multilayer (Al 2 O 3 +TiN) x Al 2 O 3 are removed.
- FIG. 3 is a schematic of the cross-section of the edge with a post-treatment according to prior art.
- FIG. 4 is a SEM picture of the edge post-treated according to the invention.
- FIG. 5 is a SEM picture of the post-treated edge of reference with thicker individual alumina layers (Insert D).
- the invention relates to a WC+Co-based cemented carbide substrate with additions of cubic carbides, a specific grain size range of the WC grains, a specific composition range of WC+Co and a coating on the cemented carbide substrate including an innermost thin layer of equiaxed TiC x N y O z followed by a layer of columnar TiC x N y O z , a thin layer of equiaxed TiC x N y O z , a multilayer with a periodic variation of TiC x N y O z and Al 2 O 3 layers (x+y+z ⁇ 1l) and an outermost layer of TiC x N y (x+y ⁇ 1). At least the non-oxide outermost layer in areas in direct contact with material from the work-piece around the cutting edge is missing.
- the composition of the cemented carbide substrate should be from about 7 to about 10.5 wt % Co, preferably from about 8.0 to about 9.5 wt % Co, and from about 0.2 to about 1.6 wt % cubic carbides, preferably from about 0.4 to about 1.0 wt % cubic carbides of the metals Ta, Nb and Ti and possibly other carbides of the elements from group IVb, Vb or VIb of the periodic table and balance tungsten carbide (WC).
- the preferred average grain size of the WC is from about 1.5 to about 3.5 ⁇ m, preferably from about 1.9 to about 2.1 ⁇ m.
- the cemented carbide substrate has a cubic carbide depleted and binder enriched volume near the surface.
- the measured distance from the surface should be from about 5 to about 50 ⁇ m until the end of the cubic carbide depletion.
- the composition comprises from about 7.0 to about 10.5 wt % Co and from about 4.0 to about 9.0 wt % cubic carbides and balance tungsten carbide (WC).
- Said cubic carbides may contain substantial amounts of N and O such that certain microstructural constituents should be referred to as e.g. carbonitride or oxycarbonitride.
- the cubic carbides are preferably Nb, Ta and Ti but may include carbides of elements from group IVb, Vb or VIb of the periodic table.
- the amount of N should be in the range of from about 0.01 to about 0.2 wt %.
- the hard and wear resistant refractory coating (FIG. 1) deposited on the cemented carbide substrate according to the present invention comprises:
- a first, innermost layer (A) of TiC x N y O z with x+y+z ⁇ 1, preferably y>x and z ⁇ 0.2, most preferably y>0.8 and z 0, with equiaxed grains with size ⁇ 0.5 ⁇ m and a total thickness ⁇ 1.5 ⁇ m but >0.1 ⁇ m preferably from about 0.1 to about 0.6 ⁇ m.
- a second layer (B) of TiC x N y O z with x+y+z ⁇ 1, preferably with z 0, x>0.3 and y>0.3, most preferably x>0.5, with a thickness of from about 0.4 to about 3.9 ⁇ m, preferably from about 1.5 to about 3.0 ⁇ m with columnar grains.
- a third layer (C) of TiC x N y O z with x+y+z ⁇ 1, preferably y>x and z ⁇ 0.2, most preferably y>0.8 and z 0, with equiaxed grains with size ⁇ 0.5 ⁇ m and a total thickness ⁇ 1.5 ⁇ m but >0.1 ⁇ m, preferably from about 0.2 to about 0.8 ⁇ m in a first embodiment.
- This layer (C) can be omitted in a second embodiment.
- the total thickness of the layers A+B+C is from about 0.7 to about 4.5 ⁇ m, preferably from about 1.2 to about 4.0 ⁇ m.
- the layers A and C are each thinner than the layer B.
- a multilayer (D) consisting of a plurality of alternating Al 2 O 3 and TiC x N y O z (x+y+z ⁇ 1) layers, preferably ⁇ -Al 2 O 3 and TiN layers.
- the innermost and the outermost layer of the multilayer sequence are Al 2 O 3 -layers.
- the total number of layers, including both the TiC x N y O z - and Al 2 O 3 -layers, is between about 5 and about 31, preferably about 11 and about 15 layers.
- the Al 2 O 3 -layers have an individual layer thickness of ⁇ 0.5 ⁇ m, preferably from about 0.2 to about 0.5 ⁇ m.
- the TiC x N y O z -layers have an individual layer thickness of from about 0.01 to about 0.2 ⁇ m, preferably from about 0.02 to about 0.15 ⁇ m.
- the total thickness of the multilayer is from about 1.0 to about 4.0 ⁇ m, preferably from about 1.5 to about 3.5 ⁇ m.
- the grain size of the Al 2 O 3 -layer is equal to or less than the thickness of the Al 2 O 3 -layer.
- an outermost layer system consisting of one or several layers in sequence of TiC x N y (x+y ⁇ 1) or combinations thereof, preferably three layers in sequence of TiN, TiC, and TiN.
- the total thickness is ⁇ 2.0 ⁇ m but >0.1 ⁇ m, preferably from about 0.2 to about 1.0 ⁇ m.
- the total thickness of the layers A-E is from about 2.0 to about 8.0 ⁇ m, preferably from about 4.0 to about 7.0 ⁇ m.
- the outermost part of the coating is missing around the edge such that this area corresponds to the chip contact on the rake side and the contact with the work piece on the flank side.
- this uncoated area correspond to the primary land on the rake side when a primary land exists on the geometry at hand such that the coating is missing a distance from a point defined in FIG. 2. 2 with a perspective perpendicular to the insert face planes on the rake face “a” and on the flank face “b”. These distances depend on different insert geometries and insert sizes, etc., but on the rake face, preferably correspond to 0.03 ⁇ a ⁇ 0.9 mm and 0.02 ⁇ b ⁇ 0.2 mm, independent of the existence of a primary land or not. In any case, a>b, preferably a>1.5b.
- the layer E is missing. In another embodiment, both layers D and E are missing in those parts of the area.
- the removal of the outermost layer (E) at the edge-line will expose the Al 2 O 3 layers in layers along the edge line.
- the edge-line is defined as the edge-honed portion of the cutting tool insert.
- the untreated edge-line is illustrated in FIG. 2. 1 and the post-treated edge-line is illustrated in FIGS. 2. 2 and 2 . 3 . It is preferable that only the non-oxide top-layer and parts of the multilayer are removed.
- the TiC x N y O z layers (A+B+C) may, however, be visible on minor parts of the edge line (FIG. 2. 3 ).
- the cemented carbide body is mainly produced by mixing of powders, ball milling, spray-drying, some pressing method followed by sintering according to conventional methods and pre-treatment before coating.
- the cemented carbide substrate is made in such a way that a cubic carbide depleted and binder phase enriched volume near the surface is obtained by sintering in vacuum after the addition of a small amount of nitrogen.
- the measured distance from the surface should be from about 5 to about 50 ⁇ m until the end of the cubic carbide depletion.
- the composition comprises from about 7.0 to about 10.5 wt % Co and from about 4.0 to about 9.0 wt % cubic carbides and balance tungsten carbide (WC).
- Said cubic carbides may contain substantial amounts of N and O such that certain microstructural constituents should be referred to as, e.g., carbonitride or oxycarbonitride.
- the cubic carbides are preferably Nb, Ta and Ti but may include carbides of elements from group IVb, Vb or VIb of the periodic table.
- the amount of N in the substrate should be in the range of from about 0.01 to about 0.2 wt %.
- a first (innermost) layer(A) of TiC x N y O z with x+y+z ⁇ 1, preferably y>x and z ⁇ 0.2, most preferably y>0.8 and z 0, with equiaxed grains with size ⁇ 0.5 ⁇ m and a total thickness ⁇ 1.5 ⁇ m but >0.1 ⁇ m using known chemical vapor deposition, CVD, methods.
- a layer of TiC x N y O z (B) with x+y+z ⁇ 1, preferably with z 0, x>0.3 and y>0.3 with a thickness of from about 0.4 to about 3.9 ⁇ m, preferably from about 1.5 to about 3.0 ⁇ m with columnar grains, using preferably a moderate temperature CVD, MTCVD, technique (using acetonitrile as the carbon and nitrogen source for forming the layer in the temperature range of from about 700 to about 900° C.).
- CVD moderate temperature CVD
- MTCVD technique
- the exact conditions depend to a certain extent on the design of the equipment used but are within the purview of the skilled artisan.
- a layer of TiC x N y O z (C) with x+y+z ⁇ 1, preferably y>x and z ⁇ 0.2, most preferably y>0.8 and z 0, with equiaxed grains with size ⁇ 0.5 ⁇ m and a total thickness ⁇ 1.5 ⁇ m but >0.1 ⁇ m using known CVD-methods.
- This layer (C) can be omitted in another embodiment.
- the total thickness of the layers A+B+C is from about 0.7 to about 4.5 ⁇ m, preferably from about 1.2 to about 4.0 ⁇ m.
- the layers A and C are each thinner than layer B.
- a multilayer(D) consisting of a plurality of alternating Al 2 O 3 and TiC x N y O z (x+y+z ⁇ 1l) layers, preferably ⁇ -Al 2 O 3 - and TiN-layers, using known CVD-methods.
- the innermost and the outermost layer of the multilayer sequence are Al 2 O 3 -layers.
- the total number of layers, including both the TiC x N y O z - and Al 2 O 3 -layers, is between about 5 and about 31, preferably about 11 and about 15 layers.
- the Al 2 O 3 -layers have an individual layer thickness of ⁇ 0.5 ⁇ m, preferably from about 0.2 to about 0.5 ⁇ m.
- the TiC x N y O z -layers have an individual layer thickness of from about 0.01 to about 0.2 ⁇ m, preferably from about 0.02 to about 0.15 ⁇ m.
- the total thickness of the multilayer is from about 1.0 to about 4.0 ⁇ m, preferably from about 1.5 to about 3.5 ⁇ m.
- the grain size of the Al 2 O 3 -layer is equal to or less than the thickness of the Al 2 O 3 -layer.
- an outermost layer system(E) consisting of one or several layers in sequence of TiC x N y (x+y ⁇ 1) or combinations thereof using known CVD-methods.
- the total thickness is ⁇ 1.5 ⁇ m.
- the total thickness of layers A-E is from about 2.0 to about 8.0 ⁇ m.
- the coating is mechanically post-treated to expose the multilayer along the edge line by a brushing, blasting, grinding operation or combinations thereof such that the areas on the rake and flank face with chip and work piece contact respectively have been treated.
- two nylon brushes containing SiC grains with settings and insert positioning such that one brush mainly brushes the rake side and the other mainly the flank side to achieve the desired properties on the flank and rake face of the insert.
- Insert A Cemented carbide turning inserts according to the invention with the composition 8.75 wt % Co, 1.17 wt % Ta, 0.29 wt % Nb and balance made up by WC and with an average WC grain size of 2.0 ⁇ m were coated with 0.5 ⁇ m TiN (innermost layer), 2.2 ⁇ m columnar Ti(C,N), and 0.5 ⁇ m equiaxed TiN, 2.2 ⁇ m ( ⁇ -Al 2 O 3 +TiN) 6 ⁇ -Al 2 O 3 multilayer with 250 nm thick ⁇ -Al 2 O 3 -layers and 80 nm thick TiN-layers and an outermost layer of 0.5 ⁇ m TiN+TiC+TiN.
- Insert D (Comparative) Identical substrates to C were coated with 0.5 ⁇ m TiN (innermost layer), 2.3 ⁇ m columnar Ti(C,N), a 1.9 ⁇ m ( ⁇ -Al 2 O 3 +TiN) 3 ⁇ -Al2O3 multilayer, and an outermost layer of 0.5 ⁇ m TiN.
- Insert F Cemented carbide turning inserts having 7.5 wt % Co, 2.72 wt % Ta, 0.44 wt % Nb, 1.83 wt % Ti, 0.09 wt % N and balance made up by WC and with an average grain size of 2.0 ⁇ m and with a binder phase enriched and cubic carbide free zone 26 ⁇ m from the surface were coated with 0.5 ⁇ m TiN (innermost layer), 2.2 ⁇ m columnar Ti(C,N), and 0.5 ⁇ m equiaxed TiN, 2.2 ⁇ m ( ⁇ -Al 2 O 3 +TiN) 6 ⁇ -Al 2 O 3 multilayer and an outermost layer of 0.5 ⁇ m TiN+TiC+TiN.
- the coating was post-treated along the edge line with nylon brushes containing SiC grains.
- Insert G (Prior Art) Commercial cemented carbide turning inserts having 7.5 wt % Co, 2.72 wt % Ta, 0.44 wt % Nb, 1.83 wt % Ti, 0.09 wt % N and balance made up by WC and with an average grain size of 2.0 ⁇ m and with a binder phase enriched and cubic carbide free zone 26 ⁇ m from the surface were coated with an innermost 0.5 ⁇ m equiaxed TiN layer, 7.5 ⁇ m columnar Ti(C,N), 1.2 ⁇ m ⁇ -Al 2 O 3 , and an outermost layer of 0.5 ⁇ m TiN+TiC+TiN.
- the coating was brushed along the edge line with nylon straw brushes containing SiC grains.
- Inserts from A and B were tested in a turning operation. Operation: Axial and facial turning in a bar Work piece material: Austenitic stainless steel AISI 316L Cutting Speed: 225 m/min Feed rate: 0.3 mm/rev Depth of cut: 2.0 mm Insert style: CNMG120408-MM Results: Tool life (min) Insert A: (invention) ca 10 Insert B: (prior art) ca 6
- Tool life criterion was maximum flank wear 0.3 mm of the cutting edge line. The wear develops irregularly due to local plastic deformation. This example shows the improvement in plastic deformation resistance.
- Inserts from A and B were tested in a turning operation. Operation: Intermittent cutting of an assembly part Work piece material: Austenitic stainless steel, AISI316L Cutting speed: 160 m/min Feed rate: 0.2-0.3 mm/rev Depth of cut: 0.5-1.5 mm Insert style: SNMG120412-MR Results: Tool life (min) Insert A: (invention) 8.2 Insert B: (prior art) 4.2
- Inserts from A and B were tested in a turning operation. Operation: Continuous cutting in a cast ring Work piece material: Austenitic stainless steel, AISI316L Cutting speed: 110 m/min Feed rate: 0.3 mm/rev Depth of cut: 3.5 mm Insert style: CNMG120412-MR Results: Tool life (min) Insert A: (invention) 18.6 Insert B: (prior art) 12.4
- Inserts from A and B were tested in a turning operation. Operation: Continuous cutting of a housing Work piece material: Duplex stainless steel, SS2377 Cutting speed: 110 m/min Feed rate: 0.3 mm/rev Depth of cut: 1.35 mm Insert style: WNMG080412-MR Results: Tool life (min) Insert A: (invention) 46 Insert B: (prior art) 24
- Inserts from A and B were tested in a turning operation. Operation: Intermittent cutting of a cast Work piece material: Austenitic stainless steel, AISI316 Cutting speed: 150-200 m/min Feed rate: 0.1-0.15 mm/rev Depth of cut: 2.0 mm Insert style: CNMG120412-PR Results: Tool life (items) Insert A: (invention) 7 Insert B: (prior art) 2
- Inserts from C and D were tested in a turning operation. Operation: Facing of a bar Work piece material: Austenitic stainless steel, AISI304L Cutting speed: 140 m/min Feed rate: 0.36 mm/rev Depth of cut: maximum 4 mm Insert style: CNMG120408-MM Results: Wear pattern Insert C: (reference) Limited flaking on rake (FIG. 4) Insert D: (reference) Widespread flaking on rake (FIG. 5)
- Inserts from C and E were tested in a turning operation. Operation: Combined facing and longitudinal turning Work piece material: Austenitic stainless steel, AISI316Ti Cutting speed: 100-120 m/min Feed rate: 0.3 mm/rev Depth of cut: 2.0 mm Insert style: CNMG120408-MM Results: Total damaged edge outside cut Insert C: (reference) 11.5 mm Insert E: (prior art) 14.7 mm
- Main wears are notch wear of the cutting depth and chipping outside the part of the edge in cut.
- the example shows that the thin multilayer coating adds edge toughness compared to a coating according to prior art.
- Inserts from C and E were tested in a turning operation. Operation: Combined facing and longitudinal turning Work piece material: Austenitic stainless steel, AISI304L Cutting speed: 225 m/min Feed rate: 0.3 mm/rev Depth of cut: 2.0 mm Insert style: CNMG120408-MM Results: Tool life (min) Insert C: (reference) 18 Insert E: (prior art) 13
- Tool life criterion was maximum flank wear 0.3 mm of the cutting edge line. The wear develops irregularly due to local plastic deformation. This example shows that the thin multilayer coating add plastic deformation resistance compared to a coating according to prior art in this operation.
- Inserts from F and G were tested in a turning operation. Operation: Continuous cutting in a forged component Work piece material: Austenitic stainless steel, AISI316L Cutting speed: 200 m/min Feed rate: 0.3 mm/rev Depth of cut: 2.0 mm Insert style: CNMG120416-MM Results: Tool life (pcs) Insert F: (invention) 32 Insert G: (prior art) 19
Abstract
Description
- This application claims priority under 35 U.S.C. § 119 to Swedish Application No. 0300175-7 filed in Sweden on Jan. 24, 2003; the entire contents of which is hereby incorporated by reference.
- The present invention relates to a coated cemented carbide cutting tool insert for the machining in general of steel in applications having high requirements on wear resistance and toughness behaviour of the cutting edge. The tool is particularly suitable for the turning of stainless steels.
- When cemented carbide cutting tools are used in the machining of steels, the tool is worn by different mechanisms such as abrasive and chemical wear, chipping and fracturing of the cutting edge. The cutting of stainless steel is considered to be a particularly difficult machining operation since in addition to the above mentioned wear mechanisms, adhesive wear is also prominent. Adhesive wear is obtained when smearing materials like stainless steels continuously adhere to and tear off material from the cutting edge during the cutting operation. A short tool life is therefore very frequent when machining stainless steels. Furthermore, when cutting stainless steels at high cutting speeds, the thermal energy transferred to the cutting edge is considerable and the tool edge may partly or entirely deform plastically. This mode of deterioration of the cutting edge is known as plastic deformation wear. A large requirement of plastic deformation resistance is in clear contrast to a large requirement of edge toughness.
- Multilayer coatings comprising first and second coating layers of different materials which are alternately laminated on the substrate, each of the first coating layers having a first thickness and each of the second coating layers having a second thickness are known. The two layers should preferably have a different crystal structure and/or at least different lattice spacings. One example of such a structure is when the Al2O3 growth periodically is interrupted by a short TiN deposition process resulting in a (Al2O3+TiN)x multilayer structure see e.g. Proceedings of the 12th European CVD Conference page pr.8-349. GB 2048960A discloses a multilayer coating with a multiplicity of alternating layers of 0.02 to 0.1 μm consisting of hard material of different compositions. U.S. Pat. No. 4,599,281 discloses a multilayer coating with alternating layers of an aluminium-boron mixed oxide and another oxide layer of e g Ti(C,N,O). Dreyer and Kolaska, Metals Society (Book 278), London, England (1982) 112-117 report an A—O—N multilayer. In U.S. Pat. No. 4,984,940 Bryant et al. disclose a cutting insert composed of a cemented carbide substrate with 6.1-6.5 wt % cobalt, a coating including a base layer of titaniumcarbonitride followed by a multilayered coating consisting of a plurality of alumina layers. A cemented carbide substrate with a coating comprising 6-8 alumina layers is also claimed in U.S. Pat. No. 5,700,569. WO 99/58738 describes a tool consisting of a hard wear resistant substrate and a CVD multilayer of about 50 layers. EP-A-1103635 claims a cutting tool consisting of a cemented carbide substrate with 9.0-10.9 wt % cobalt and a coating comprising a medium temperature CVD (MTCVD) deposited TiCN-layer and a multilayer composed of totally 7-41 layers of α-alumina and TiN or Ti(C,N). EP-A-1245698, EP-A-1245700, and EP-1209255 also relate to multilayer coatings.
- Smoothing of coatings by mechanical post treatment in order to e g minimize the friction between the tool and the workpiece is disclosed in EP-A-127416, EP-A-298729, EP-A-693574 and EP-A-683244.
- It is an object of the present invention to provide a cutting tool insert able to simultaneously withstand all the above mentioned wear modes.
- It is a further object of the present invention to eliminate the deficiencies of prior art tool products and to provide a high performance cutting tool.
- It is a still further object of the present invention to provide a tool with excellent cutting performance in demanding stainless steel turning operations.
- In the aspect of the present invention, there is provided a coated cemented carbide cutting tool insert, said coating comprising a first, innermost layer system of at least two layers of TiCxNyOz with x+y+z≦1; and a second multilayer system comprising from about 5 to about 31 alternating layers of Al2O3 and TiCxNyOz (x+y+z≦1), the Al2O3-layers having an individual layer thickness of <0.5 μm and the TiCxNyOz-layers from about 0.01 to about 0.2 μm with a total thickness of the multilayer from about 1.0 to about 4.0 μm, and wherein the multilayer is exposed along the edge line and into the rake and flank face, such that the exposure on the rake face (a) is greater than about 0.03 and less than about 0.9 mm, the exposure on the flank face (b) is greater than about 0.02 and less than about 0.2 mm and a>b.
- FIG. 1. is a scanning electron micrograph (SEM) of a cross-section of the coating according to the present invention in which:
- A.=TiN,
- B.=columnar Ti(C,N),
- C.=TiN,
- D.=multilayer (Al2O3+TiN)6Al2O3 and
- E.=TiN+TiC+TiN.
- FIG. 2.1 is a schematic of the cross-section of the edge without a post-treatment.
- FIG. 2.2 is a schematic of the cross-section of the edge with a post-treatment according to the invention where the outermost coating E is removed.
- FIG. 2.3 is a schematic of the cross-section of the edge with a post-treatment according to the invention where the outermost coating E and the multilayer (Al2O3+TiN)xAl2O3 are removed.
- FIG. 3 is a schematic of the cross-section of the edge with a post-treatment according to prior art.
- FIG. 4 is a SEM picture of the edge post-treated according to the invention.
- FIG. 5 is a SEM picture of the post-treated edge of reference with thicker individual alumina layers (Insert D).
- More specifically, the invention relates to a WC+Co-based cemented carbide substrate with additions of cubic carbides, a specific grain size range of the WC grains, a specific composition range of WC+Co and a coating on the cemented carbide substrate including an innermost thin layer of equiaxed TiCxNyOz followed by a layer of columnar TiCxNyOz, a thin layer of equiaxed TiCxNyOz, a multilayer with a periodic variation of TiCxNyOz and Al2O3 layers (x+y+z≦1l) and an outermost layer of TiCxNy (x+y≦1). At least the non-oxide outermost layer in areas in direct contact with material from the work-piece around the cutting edge is missing.
- The composition of the cemented carbide substrate should be from about 7 to about 10.5 wt % Co, preferably from about 8.0 to about 9.5 wt % Co, and from about 0.2 to about 1.6 wt % cubic carbides, preferably from about 0.4 to about 1.0 wt % cubic carbides of the metals Ta, Nb and Ti and possibly other carbides of the elements from group IVb, Vb or VIb of the periodic table and balance tungsten carbide (WC). The preferred average grain size of the WC is from about 1.5 to about 3.5 μm, preferably from about 1.9 to about 2.1 μm.
- In an alternative embodiment, the cemented carbide substrate has a cubic carbide depleted and binder enriched volume near the surface. The measured distance from the surface should be from about 5 to about 50 μm until the end of the cubic carbide depletion. In this embodiment the composition comprises from about 7.0 to about 10.5 wt % Co and from about 4.0 to about 9.0 wt % cubic carbides and balance tungsten carbide (WC). Said cubic carbides may contain substantial amounts of N and O such that certain microstructural constituents should be referred to as e.g. carbonitride or oxycarbonitride. The cubic carbides are preferably Nb, Ta and Ti but may include carbides of elements from group IVb, Vb or VIb of the periodic table. The amount of N should be in the range of from about 0.01 to about 0.2 wt %.
- The hard and wear resistant refractory coating (FIG. 1) deposited on the cemented carbide substrate according to the present invention comprises:
- a first, innermost layer (A) of TiCxNyOz with x+y+z≦1, preferably y>x and z<0.2, most preferably y>0.8 and z=0, with equiaxed grains with size <0.5 μm and a total thickness <1.5 μm but >0.1 μm preferably from about 0.1 to about 0.6 μm.
- a second layer (B) of TiCxNyOz with x+y+z≦1, preferably with z=0, x>0.3 and y>0.3, most preferably x>0.5, with a thickness of from about 0.4 to about 3.9 μm, preferably from about 1.5 to about 3.0 μm with columnar grains.
- a third layer (C) of TiCxNyOz with x+y+z≦1, preferably y>x and z<0.2, most preferably y>0.8 and z=0, with equiaxed grains with size <0.5 μm and a total thickness <1.5 μm but >0.1 μm, preferably from about 0.2 to about 0.8 μm in a first embodiment. This layer (C) can be omitted in a second embodiment.
- the total thickness of the layers A+B+C is from about 0.7 to about 4.5 μm, preferably from about 1.2 to about 4.0 μm. Preferably, the layers A and C are each thinner than the layer B.
- a multilayer (D) consisting of a plurality of alternating Al2O3 and TiCxNyOz (x+y+z≦1) layers, preferably κ-Al2O3 and TiN layers. The innermost and the outermost layer of the multilayer sequence are Al2O3-layers. The total number of layers, including both the TiCxNyOz- and Al2O3-layers, is between about 5 and about 31, preferably about 11 and about 15 layers. The Al2O3-layers have an individual layer thickness of <0.5 μm, preferably from about 0.2 to about 0.5 μm. The TiCxNyOz-layers have an individual layer thickness of from about 0.01 to about 0.2 μm, preferably from about 0.02 to about 0.15 μm. The total thickness of the multilayer is from about 1.0 to about 4.0 μm, preferably from about 1.5 to about 3.5 μm. The grain size of the Al2O3-layer is equal to or less than the thickness of the Al2O3-layer.
- an outermost layer system (E) consisting of one or several layers in sequence of TiCxNy (x+y≦1) or combinations thereof, preferably three layers in sequence of TiN, TiC, and TiN. The total thickness is <2.0 μm but >0.1 μm, preferably from about 0.2 to about 1.0 μm.
- the total thickness of the layers A-E is from about 2.0 to about 8.0 μm, preferably from about 4.0 to about 7.0 μm.
- The outermost part of the coating is missing around the edge such that this area corresponds to the chip contact on the rake side and the contact with the work piece on the flank side. Most preferably this uncoated area correspond to the primary land on the rake side when a primary land exists on the geometry at hand such that the coating is missing a distance from a point defined in FIG. 2.2 with a perspective perpendicular to the insert face planes on the rake face “a” and on the flank face “b”. These distances depend on different insert geometries and insert sizes, etc., but on the rake face, preferably correspond to 0.03<a<0.9 mm and 0.02<b<0.2 mm, independent of the existence of a primary land or not. In any case, a>b, preferably a>1.5b. In one embodiment, the layer E is missing. In another embodiment, both layers D and E are missing in those parts of the area.
- The removal of the outermost layer (E) at the edge-line will expose the Al2O3 layers in layers along the edge line. The edge-line is defined as the edge-honed portion of the cutting tool insert. The untreated edge-line is illustrated in FIG. 2.1 and the post-treated edge-line is illustrated in FIGS. 2.2 and 2.3. It is preferable that only the non-oxide top-layer and parts of the multilayer are removed. The TiCxNyOz layers (A+B+C) may, however, be visible on minor parts of the edge line (FIG. 2.3).
- The cemented carbide body is mainly produced by mixing of powders, ball milling, spray-drying, some pressing method followed by sintering according to conventional methods and pre-treatment before coating.
- In an alternative embodiment, the cemented carbide substrate is made in such a way that a cubic carbide depleted and binder phase enriched volume near the surface is obtained by sintering in vacuum after the addition of a small amount of nitrogen. The measured distance from the surface should be from about 5 to about 50 μm until the end of the cubic carbide depletion. In this embodiment, the composition comprises from about 7.0 to about 10.5 wt % Co and from about 4.0 to about 9.0 wt % cubic carbides and balance tungsten carbide (WC). Said cubic carbides may contain substantial amounts of N and O such that certain microstructural constituents should be referred to as, e.g., carbonitride or oxycarbonitride. The cubic carbides are preferably Nb, Ta and Ti but may include carbides of elements from group IVb, Vb or VIb of the periodic table. The amount of N in the substrate should be in the range of from about 0.01 to about 0.2 wt %.
- The body is then coated with
- a first (innermost) layer(A) of TiCxNyOz with x+y+z≦1, preferably y>x and z<0.2, most preferably y>0.8 and z=0, with equiaxed grains with size <0.5 μm and a total thickness <1.5 μm but >0.1 μm using known chemical vapor deposition, CVD, methods.
- a layer of TiCxNyOz(B) with x+y+z≦1, preferably with z=0, x>0.3 and y>0.3 with a thickness of from about 0.4 to about 3.9 μm, preferably from about 1.5 to about 3.0 μm with columnar grains, using preferably a moderate temperature CVD, MTCVD, technique (using acetonitrile as the carbon and nitrogen source for forming the layer in the temperature range of from about 700 to about 900° C.). The exact conditions depend to a certain extent on the design of the equipment used but are within the purview of the skilled artisan.
- a layer of TiCxNyOz(C) with x+y+z≦1, preferably y>x and z<0.2, most preferably y>0.8 and z=0, with equiaxed grains with size <0.5 μm and a total thickness <1.5 μm but >0.1 μm using known CVD-methods. This layer (C) can be omitted in another embodiment.
- The total thickness of the layers A+B+C is from about 0.7 to about 4.5 μm, preferably from about 1.2 to about 4.0 μm. Preferably, the layers A and C are each thinner than layer B.
- a multilayer(D) consisting of a plurality of alternating Al2O3 and TiCxNyOz (x+y+z≦1l) layers, preferably κ-Al2O3- and TiN-layers, using known CVD-methods. The innermost and the outermost layer of the multilayer sequence are Al2O3-layers. The total number of layers, including both the TiCxNyOz- and Al2O3-layers, is between about 5 and about 31, preferably about 11 and about 15 layers. The Al2O3-layers have an individual layer thickness of <0.5 μm, preferably from about 0.2 to about 0.5 μm. The TiCxNyOz-layers have an individual layer thickness of from about 0.01 to about 0.2 μm, preferably from about 0.02 to about 0.15 μm. The total thickness of the multilayer is from about 1.0 to about 4.0 μm, preferably from about 1.5 to about 3.5 μm. The grain size of the Al2O3-layer is equal to or less than the thickness of the Al2O3-layer.
- preferably, an outermost layer system(E) consisting of one or several layers in sequence of TiCxNy (x+y≦1) or combinations thereof using known CVD-methods. The total thickness is <1.5 μm.
- G. the total thickness of layers A-E is from about 2.0 to about 8.0 μm.
- The coating is mechanically post-treated to expose the multilayer along the edge line by a brushing, blasting, grinding operation or combinations thereof such that the areas on the rake and flank face with chip and work piece contact respectively have been treated.
- In the preferred method, two nylon brushes containing SiC grains with settings and insert positioning such that one brush mainly brushes the rake side and the other mainly the flank side to achieve the desired properties on the flank and rake face of the insert.
- The invention is additionally illustrated in connection with the following Examples, which are to be considered as illustrative of the present invention. It should be understood, however, that the invention is not limited to the specific details of the Examples.
- The following inserts and examples are selected to exemplify the advantages with the invention. These examples are summarised in Table 1.
- The presented inserts have been tested with identical conditions in each example.
- Insert A. Cemented carbide turning inserts according to the invention with the composition 8.75 wt % Co, 1.17 wt % Ta, 0.29 wt % Nb and balance made up by WC and with an average WC grain size of 2.0 μm were coated with 0.5 μm TiN (innermost layer), 2.2 μm columnar Ti(C,N), and 0.5 μm equiaxed TiN, 2.2 μm (κ-Al2O3+TiN)6κ-Al2O3 multilayer with 250 nm thick κ-Al2O3-layers and 80 nm thick TiN-layers and an outermost layer of 0.5 μm TiN+TiC+TiN. The coating was post-treated along the edge line with nylon brushes containing SiC grains. The outermost coating was removed a=0.1 mm and b=0.05 mm into the rake and flank face.
- Insert B. (Prior Art) Commercial cemented carbide turning inserts having 10.5 wt % Co, 1.16 wt % Ta, 0.28 wt % Nb and balance made up by WC and with an average grain size of 1.7 μm, was coated with an innermost 0.5 μm equiaxed TiN layer, 4.0 μm columnar Ti(C,N), 1.0 μm κ-Al2O3, and an outermost layer of 0.5 μm TiN+TiC+TiN. The coating was brushed along the edge line with nylon straw brushes containing SiC grains. The outermost coating was removed a=0.025 mm and b=0.05 mm along the edge line according to prior art.
- Insert C. (Comparative) Cemented carbide turning inserts with the composition 9.15 wt % Co, 1.17 wt % Ta, 0.29 wt % Nb and balance made up by WC and with an average WC grain size of 1.7 μm, were coated with 0.5 μm TiN (innermost layer), 2.2 μm columnar TiCN, a 1.8 μm (κ-Al2O3+TiN)5κ-Al2O3 multilayer, and an outermost layer of 0.5 μm TiN. The coating was post-treated along the edge line with nylon brushes containing SiC grains. The outermost coating was removed a=0.025 mm and b=0.05 mm along the edge line, according to prior art.
- Insert D. (Comparative) Identical substrates to C were coated with 0.5 μm TiN (innermost layer), 2.3 μm columnar Ti(C,N), a 1.9 μm (κ-Al2O3+TiN)3κ-Al2O3 multilayer, and an outermost layer of 0.5 μm TiN. The coating was post-treated along the edge line with nylon brushes containing SiC grains. The outermost coating was removed a=0.025 mm and b=0.05 mm along the edge line according to prior art.
- Insert E. (Prior Art) Identical substrates to C were coated with an innermost 0.5 μm equiaxed TiN layer, 2.2 μm columnar Ti(C,N), 1.5 μm κ-Al2O3, and an outermost layer of 0.5 μm TiN+TiC+TiN. The outermost coating was removed a=0.025 mm and b=0.05 mm along the edge line according to prior art.
- Insert F. Cemented carbide turning inserts having 7.5 wt % Co, 2.72 wt % Ta, 0.44 wt % Nb, 1.83 wt % Ti, 0.09 wt % N and balance made up by WC and with an average grain size of 2.0 μm and with a binder phase enriched and cubic carbide free zone 26 μm from the surface were coated with 0.5 μm TiN (innermost layer), 2.2 μm columnar Ti(C,N), and 0.5 μm equiaxed TiN, 2.2 μm (κ-Al2O3+TiN)6κ-Al2O3 multilayer and an outermost layer of 0.5 μm TiN+TiC+TiN.
- The coating was post-treated along the edge line with nylon brushes containing SiC grains. The outermost coating was removed a=0.1 mm and b=0.05 mm into the rake and flank face.
- Insert G. (Prior Art) Commercial cemented carbide turning inserts having 7.5 wt % Co, 2.72 wt % Ta, 0.44 wt % Nb, 1.83 wt % Ti, 0.09 wt % N and balance made up by WC and with an average grain size of 2.0 μm and with a binder phase enriched and cubic carbide free zone 26 μm from the surface were coated with an innermost 0.5 μm equiaxed TiN layer, 7.5 μm columnar Ti(C,N), 1.2 μm κ-Al2O3, and an outermost layer of 0.5 μm TiN+TiC+TiN.
- The coating was brushed along the edge line with nylon straw brushes containing SiC grains. The outermost coating was removed a=0.025 mm and b=0.05 mm along the edge line as disclosed in EP-A-693574.
- Inserts from A and B were tested in a turning operation.
Operation: Axial and facial turning in a bar Work piece material: Austenitic stainless steel AISI 316L Cutting Speed: 225 m/min Feed rate: 0.3 mm/rev Depth of cut: 2.0 mm Insert style: CNMG120408-MM Results: Tool life (min) Insert A: (invention) ca 10 Insert B: (prior art) ca 6 - Comment: Tool life criterion was maximum flank wear 0.3 mm of the cutting edge line. The wear develops irregularly due to local plastic deformation. This example shows the improvement in plastic deformation resistance.
- Inserts from A and B were tested in a turning operation.
Operation: Intermittent cutting of an assembly part Work piece material: Austenitic stainless steel, AISI316L Cutting speed: 160 m/min Feed rate: 0.2-0.3 mm/rev Depth of cut: 0.5-1.5 mm Insert style: SNMG120412-MR Results: Tool life (min) Insert A: (invention) 8.2 Insert B: (prior art) 4.2 - Comment: The wear in this test was flank wear, thermal cracks, chipping. The tool-life-determining criterion is chipping i.e. edge toughness. Consequently it shows improved edge toughness in combination with maintained properties in other wear modes.
- Inserts from A and B were tested in a turning operation.
Operation: Continuous cutting in a cast ring Work piece material: Austenitic stainless steel, AISI316L Cutting speed: 110 m/min Feed rate: 0.3 mm/rev Depth of cut: 3.5 mm Insert style: CNMG120412-MR Results: Tool life (min) Insert A: (invention) 18.6 Insert B: (prior art) 12.4 - Comment: The criterion in this test is working through a full item taking total time in cut 6.2 min without showing excessive flank wear or edge damage. The critical wear criteria are flank wear and plastic deformation in combination.
- The insert according to the invention shows improvements in these respects.
- Inserts from A and B were tested in a turning operation.
Operation: Continuous cutting of a housing Work piece material: Duplex stainless steel, SS2377 Cutting speed: 110 m/min Feed rate: 0.3 mm/rev Depth of cut: 1.35 mm Insert style: WNMG080412-MR Results: Tool life (min) Insert A: (invention) 46 Insert B: (prior art) 24 - Comment: This test shows a clear improvement compared to prior art. It is however difficult in this example to determine one single critical wear but it can be described as a combination of flank wear, flaking on rake and edge toughness.
- Inserts from A and B were tested in a turning operation.
Operation: Intermittent cutting of a cast Work piece material: Austenitic stainless steel, AISI316 Cutting speed: 150-200 m/min Feed rate: 0.1-0.15 mm/rev Depth of cut: 2.0 mm Insert style: CNMG120412-PR Results: Tool life (items) Insert A: (invention) 7 Insert B: (prior art) 2 - Comment: This test shows improvement in toughness since the main wear criterion is edge toughness in this demanding application.
- Inserts from C and D were tested in a turning operation.
Operation: Facing of a bar Work piece material: Austenitic stainless steel, AISI304L Cutting speed: 140 m/min Feed rate: 0.36 mm/rev Depth of cut: maximum 4 mm Insert style: CNMG120408-MM Results: Wear pattern Insert C: (reference) Limited flaking on rake (FIG. 4) Insert D: (reference) Widespread flaking on rake (FIG. 5) - Comment: This example shows improved flaking resistance compared to the reference implying the importance of alumina layer thickness.
- Inserts from C and E were tested in a turning operation.
Operation: Combined facing and longitudinal turning Work piece material: Austenitic stainless steel, AISI316Ti Cutting speed: 100-120 m/min Feed rate: 0.3 mm/rev Depth of cut: 2.0 mm Insert style: CNMG120408-MM Results: Total damaged edge outside cut Insert C: (reference) 11.5 mm Insert E: (prior art) 14.7 mm - Comment: Main wears are notch wear of the cutting depth and chipping outside the part of the edge in cut.
- The example shows that the thin multilayer coating adds edge toughness compared to a coating according to prior art.
- Inserts from C and E were tested in a turning operation.
Operation: Combined facing and longitudinal turning Work piece material: Austenitic stainless steel, AISI304L Cutting speed: 225 m/min Feed rate: 0.3 mm/rev Depth of cut: 2.0 mm Insert style: CNMG120408-MM Results: Tool life (min) Insert C: (reference) 18 Insert E: (prior art) 13 - Comment: Tool life criterion was maximum flank wear 0.3 mm of the cutting edge line. The wear develops irregularly due to local plastic deformation. This example shows that the thin multilayer coating add plastic deformation resistance compared to a coating according to prior art in this operation.
- Considering example 7 this shows an improvement in these contradictory properties.
- Inserts from F and G were tested in a turning operation.
Operation: Continuous cutting in a forged component Work piece material: Austenitic stainless steel, AISI316L Cutting speed: 200 m/min Feed rate: 0.3 mm/rev Depth of cut: 2.0 mm Insert style: CNMG120416-MM Results: Tool life (pcs) Insert F: (invention) 32 Insert G: (prior art) 19 - Comment: The critical wear criteria are flank wear and plastic deformation in combination in this test. The insert according to the invention shows improvement in these respects.
TABLE 1 A (invention) B (prior art) C (outside invention) D (outside invention) E (prior art) F (invention) G (prior art) Substrate Co/Ta/Nb (wt %) 8.75/1.17/0.29 10.5/1.16/0.28 9.15/1.17/0.29 9.15/1.17/0.29 9.15/1.17/0.29 7.5/2.72/0.44 7.5/2.72/0.44 Ti/N (wt %) —/— —/— —/— —/— —/— 1.83/0.09 1.83/0.09 Coating TiN (innermost layer) 0.5 μm 0.5 μm 0.5 μm 0.5 μm 0.5 μm 0.5 μm 0.5 μm Ti (C,N) 2.2 μm 4.0 μm 2.2 μm 2.3 μm 2.2 μm 2.2 μm 7.5 μm TiN 0.5 μm — — — — 0.5 μm — (Al2O3/TiN)xAl2O3 1.0 μm 1.8 μm, x = 5 1.9 μm, x = 3 1.5 μm 2.2 μm, x = 6 1.2 μm or solid Al2O3 2.2 μm, x = 6 solid Al2O3 solid Al2O3 solid Al2O3 TiN + TiC + TiN 0.5 μm 0.5 μm 0.5 μm 0.5 μm 0.5 μm 0.5 μm 0.5 μm Post treatment Acc to Prior art Prior art Prior art Prior art Acc to Prior art invention invention Results 1. plastic deformation 10 min 6 min (tool life) 2. combined wear 8.2 min 4.2 min (tool life) 3. toughness and wear 18.6 min 12.4 min resistance (tool life) 4. toughness and 46 min 24 min adhesion (tool life) 5. toughness 7 items 2 items (no of items) 6. flaking Limited Widespread 7. edge toughness 11.5 mm 14.7 mm (damaged length) 8. plastic deformation 18 min 13 min (tool life) 9. flank wear and 32 items 19 items plastic deformation (no of items) - In conclusion it can be stated that from the result of the examples given above it is evident that by combining a cemented carbide substrate with the given composition, the selection of the multilayered coating with specific thicknesses and the special edge treatment a tool insert has been created with excellent cutting performance in that it combines much of what was believed to be contradictory properties as described in the introduction.
- The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular forms disclosed, since these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the spirit of the invention.
Claims (18)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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SE0300175-7 | 2003-01-24 | ||
SE0300175A SE526603C3 (en) | 2003-01-24 | 2003-01-24 | Coated cemented carbide insert |
Publications (2)
Publication Number | Publication Date |
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US20040180241A1 true US20040180241A1 (en) | 2004-09-16 |
US7153562B2 US7153562B2 (en) | 2006-12-26 |
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Application Number | Title | Priority Date | Filing Date |
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US10/760,387 Active 2024-06-26 US7153562B2 (en) | 2003-01-24 | 2004-01-21 | Coated cemented carbide insert |
Country Status (6)
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US (1) | US7153562B2 (en) |
EP (1) | EP1455003B1 (en) |
JP (2) | JP2004223711A (en) |
KR (1) | KR20040068476A (en) |
CN (1) | CN100478498C (en) |
SE (1) | SE526603C3 (en) |
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KR102178612B1 (en) | 2012-12-21 | 2020-11-13 | 산드빅 인터렉츄얼 프로퍼티 에이비 | Coated cutting tool and method for manufacturing the same |
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Also Published As
Publication number | Publication date |
---|---|
SE0300175D0 (en) | 2003-01-24 |
US7153562B2 (en) | 2006-12-26 |
KR20040068476A (en) | 2004-07-31 |
CN1517450A (en) | 2004-08-04 |
SE0300175L (en) | 2004-07-25 |
EP1455003A3 (en) | 2008-06-18 |
CN100478498C (en) | 2009-04-15 |
JP2004223711A (en) | 2004-08-12 |
JP5529771B2 (en) | 2014-06-25 |
JP2011067948A (en) | 2011-04-07 |
SE526603C2 (en) | 2005-10-18 |
SE526603C3 (en) | 2005-11-16 |
EP1455003B1 (en) | 2014-05-21 |
EP1455003A2 (en) | 2004-09-08 |
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